Wire electrical discharge machining (WEDM) is a demanding high-precision process for machining of hard-to-machine materials. The main issue is manufacturing errors in shape and radius of small arcs generation. In this paper, a novel model about spark variable gap sizes and nonuniform spark distribution around the wire on arced path machining is first theoretically developed using spark angle domain and WEDM dynamic analysis. Applying spark-force distributed around the wire and resulting wire deflection are estimated by the WEDM conditions influenced by plasma channel specifications, discharge frequency, wire guide clearance, wire tension, and arc radius. Total theoretical arced machining errors including wire deflection and spark gap size variation around the wire interface are calculated based on the proposed model. In addition, machining errors of straight and small arced paths are experimentally analyzed under variation of WEDM influential parameters including discharge frequency, arced path radius (150, 300 and 450 μm), and wire tension through the statistical full factorial. Comparison of the results for different sets of variable parameters shows that the theoretical values of the arced machining errors can be consistent with the experimental one by a coefficient which depends on the machining conditions and the WED machine type. Finally, based on the theoretical and experimental results, a theoretical algorithm and an operational method with mean accuracy of 84.8% are proposed for predicting and compensating the errors of WEDM on the arced paths. Findings of this research can be used in high-accurate WEDM applications and industries.
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January 2019
Research-Article
Prediction Algorithm for WEDM Arced Path Errors Based on Spark Variable Gap and Nonuniform Spark Distribution Models
Hamid Abyar,
Hamid Abyar
Department of Mechanical Engineering,
Amirkabir University of Technology,
No. 424, Hafez Avenue,
P.O. Box 15875-4413,
Tehran 1591634311, Iran
Amirkabir University of Technology,
No. 424, Hafez Avenue,
P.O. Box 15875-4413,
Tehran 1591634311, Iran
Search for other works by this author on:
Amir Abdullah,
Amir Abdullah
Department of Mechanical Engineering,
Amirkabir University of Technology,
P.O. Box 15875-4413,
Tehran 1591634311, Iran
e-mail: amirah@aut.ac.ir
Amirkabir University of Technology,
No. 424, Hafez Avenue
,P.O. Box 15875-4413,
Tehran 1591634311, Iran
e-mail: amirah@aut.ac.ir
Search for other works by this author on:
Abdolhamid Akbarzadeh
Abdolhamid Akbarzadeh
Department of Bioresource Engineering,
McGill University,
Island of Montreal, QC H9X 3V9, Canada;
Department of Mechanical Engineering,
McGill University,
Montreal, QC H3A 0C3, Canada
McGill University,
Island of Montreal, QC H9X 3V9, Canada;
Department of Mechanical Engineering,
McGill University,
Montreal, QC H3A 0C3, Canada
Search for other works by this author on:
Hamid Abyar
Department of Mechanical Engineering,
Amirkabir University of Technology,
No. 424, Hafez Avenue,
P.O. Box 15875-4413,
Tehran 1591634311, Iran
Amirkabir University of Technology,
No. 424, Hafez Avenue,
P.O. Box 15875-4413,
Tehran 1591634311, Iran
Amir Abdullah
Department of Mechanical Engineering,
Amirkabir University of Technology,
P.O. Box 15875-4413,
Tehran 1591634311, Iran
e-mail: amirah@aut.ac.ir
Amirkabir University of Technology,
No. 424, Hafez Avenue
,P.O. Box 15875-4413,
Tehran 1591634311, Iran
e-mail: amirah@aut.ac.ir
Abdolhamid Akbarzadeh
Department of Bioresource Engineering,
McGill University,
Island of Montreal, QC H9X 3V9, Canada;
Department of Mechanical Engineering,
McGill University,
Montreal, QC H3A 0C3, Canada
McGill University,
Island of Montreal, QC H9X 3V9, Canada;
Department of Mechanical Engineering,
McGill University,
Montreal, QC H3A 0C3, Canada
1Corresponding author.
Manuscript received May 17, 2018; final manuscript received October 6, 2018; published online November 26, 2018. Editor: Y. Lawrence Yao.
J. Manuf. Sci. Eng. Jan 2019, 141(1): 011011 (11 pages)
Published Online: November 26, 2018
Article history
Received:
May 17, 2018
Revised:
October 6, 2018
Citation
Abyar, H., Abdullah, A., and Akbarzadeh, A. (November 26, 2018). "Prediction Algorithm for WEDM Arced Path Errors Based on Spark Variable Gap and Nonuniform Spark Distribution Models." ASME. J. Manuf. Sci. Eng. January 2019; 141(1): 011011. https://doi.org/10.1115/1.4041779
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